Modular connector assembly for multiconductor communications cable



r w n E me 0.N am ww @n 4 me ma n X m .r e 4 M C 7 U s, 4, 3R d urn. w r l C d Z U w E D Z r w 4 .r N m R Hmmm N EMM4 Kwm.. n wh UMId @Hmm .0b. CMMMWM Em N O C Dn A L U D O M Oct. 2l, 1969 MODULAR CONNECTOR ASSEMBLY FOR MULTI- CONDUCTOR COMMUNICATIONS CABLE Edward Clarke Quackenbush, Woodbridge, Conn., as-

ignor to The Whitney Blake Company, New Haven,

onn.

Filed Jan. 4, 1968, Ser. No. 695,607 Int. Cl. H02g 3/04; H01r 13/44, 13/54 U.S. Cl. 339-36 10 Claims ABSTRACT OF THE DISCLOSURE The disclosed modular connector assembly is adapted to the terminal end of a multiconductor communications cable. The assembly consists of plural connectors serially arranged in substantial alignment with the cable longitudinal axis to present a small cross-section conductive to being threaded through conduit during installation. All but the last of the aligned connectors are through-connectors electrically terminating a portion of the cable conductors; the remaining conductors passing through to the next succeeding connector and constituting a flexible, jacketed, multiconductor cable segment joining consecutive connectors together.

BACKGROUND OF THE INVENTION In most installations of multiconductor communication cable in buildings or the like, the cable is brought in and distributed throughout the building through conduit. Where large multiconductor cable are concerned, such as those containing in excess of conductor pairs, the connectors electrically terminating the individual conductors can only be connected up after the cable has been threaded through the previously installed conduit. This is because the dimensions of the connector are larger than lthe internal dimensions of the conduit and thus cannot pass through the conduit while `connected to the terminal ends of the cable. If the connector is made elongated such that its cross-sectional dimensions permit it to be received in the conduit, its length prevents it from being threaded past bends and curves in the conduit.

As a consequence, the practice has been to thread only the cable through the conduit, bringing the conductor terminal ends to locations in the building called for in the installation. This being done, the connectors are then electrically connected to the appropriate conductor pairs making up the cable. This is an expensive procedure since these connections, both mechanical and electrical in nature, must be accomplished on the job and entirely by hand. As a consequence, the various known automated or assembly line connecting techniques cannot be utilized.

SUMMARY OF THE INVENTION The instant invention provides a multiconductor communications cable terminal end assembly of modular construction capable of being assembled at the factory using known automated and mass assembly techniques and yet isI capable of being threaded While connected to the multiconductor cable through conduit pursuant to installation. Installation costs are thereby drastically reduced, time is saved, and the possibility of improper electrical connections present when the connectors are assembled on the job is eliminated.

According to the invention, the terminal end assembly consists of one or more series arranged through-connectors. The rst in the series of through-connectors accepts the multiconductor cable and electrically terminates a portion of the conductors thereof. The remaining conductors pass through to the next through-connector, while at the United States Patent O m Patented Oct. 21, 1969 same time constituting a multiconductor cable segment ilexibly joining this next through-connector to the first. Again, a portion of the conductors of the cable segment are electrically terminated in the second through-connector while the remaining conductors pass through to the next connector. Ultimately, a final terminal electrical connector electrically terminates all of the conductors of the cable segment passed through the preceding through-connector. All of the various connectors are aligned substantially along the longitudinal axis of the cable with their contact members extending perpendicular thereto. Consequently, the connectors may be made sufficiently small such that their largest lateral dimension may be accommodated by the conduit through which the assembly is to be threaded. The cable segments flexibly joining consecutive connectors permit the connector assembly to readily flex thus allowing it to pass through bends and turns in the conduit.

Since it is found that male connectors have smaller lateral dimensions than their female counterparts, it is preferred that the connectors included in the connector assembly be of the male type. In order to protect the pins of the male connectors during threading, a pin guard is provided. The guard is secured to the connectors by screws which at the same time serve to hold the individual connectors together. Once the installation has been effected, the screws are withdrawn, the pin guards removed, and the same screws used to secure the male connectors to female connectors pursuant to being put into service.

There is further provided a novel cover for each throughconnector and the terminal connector. Each through-connector cover includes an entrance opening and an exit opening joined by a passageway therebetween. The entrance opening receives the multiconductor cable or the cable segment from a preceding through-connector while the exit opening passes the multiconductor cable segment to the next through-connector or the terminal connector. Integrally formed collars disposed adjacent the openings encircle and grip the cable or cable segments as the case may be, thereby securing the connectors to the cable.

The invention accordingly comprises an article of manufacture possessing the features, properties and the relation of elements which will be exemplified in the article hereinafter described, and the scope of the invention will be indicated in the claims.

For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawing, in which:

FIGURE 1 is a side elevational view of the modular connector assembly constructed according to one embodiment of the invention;

FIGURE 2 is a bottom view of FIGURE l FIGURE 3 is a bottom plan view of a through-connector cover member utilized in the assembly of FIG- URE l;

FIGURE 4 is an end view of the cover member of FIGURE 3 which further illustrates in phantom the manner of implementation of the integrally formed end collars;

FIGURE 5 is a longitudinal sectional view taken along line 5-5 of FIGURE 3; and

FIGURE 6 is a side-elevational View showing the assembly of a female connector to one of the male connectors of the modular connector assembly of FIG- ure 1.

`Corresponding reference numerals refer to like parts throughout the several views of the drawing.

The modular connector assembly constructed according to one embodiment of the invention is shown in FIGURES 1 and 2 terminating a 100 pair multiconductor communication cable indicated at =10. It will be appreciated that the principles of the invention may be applied to electrically terminating a multiconductor communications cable having any number of conductor pairs. However, the full advantages of the invention are realized when electrically terminating a communications cable having in excess of 25 conductor pairs.

The modular connector assembly seen in FIGURES 1 and 2 includes a plurality of through-connectors 12, 14, and 16 series arranged in substantial parallel alignment with the longitudinal axis of the multiconductor cable 10. Through-connectors 12 and 14 are joined by a jacketed multiconductor cable segment 18 while through-connectors 14 and 16 are joined by a similarly jacketed multiconductor cable segment 20. The nal connector in the connector assembly of FIGURES 1 and 2 is a terminal connector 22 joined to the preceding connector, throughconnector 16, by a jacketed multiconductor cable segment 24. The through-connectors 12, 14, and 16 are similarly constructed, except that each is somewhat scaled down in size in relation to its predecessor. Thus, throughconnector `12 is the largest, while through connector 14 is somewhat smaller and through-connector 16 is smaller still. As will be seen from the description to follow, the successive reductions in size of the through-connectors is permitted by the fact that each succeeding through-connector must handle a lesser number of conductor pairs.

Still referring to FIGURES 1 and 2, each of the through-connectors 12, 14, and 16 consists of a cover member 26, preferably formed of a semi-rigid plastic material such as polyvinyl chloride, polyethylene, etc. The cover member 26 of each through-connector is scaled down in size from the cover member of its predecessor connector. In addition to cover member 26, each through-connector includes a terminal block 28 in which are imbedded a plurality of male terminal members 30, best seen in FIGURE l in connection with throughconnector 14. A pin guard 32 is in the form of a block having a plurality of suitably arranged holes 33 into which the exposed pins 34 of the male terminal members 30 are inserted for their protection during conduit threading. As best seen in conjunction with through-connector 16 of FIGURES 1, each connector, including connector 22, is held together by a pair of diagonally opposed screws 36 extending through holes 37 in the cover member 26 and holes in terminal block 28 and then threaded into guard 32.

According to the invention, assuming the multiconductor communication cable contains 100 conductor pairs, through-connector 12 is adapted to electrically terminate of the conductor pairs and pass 75 through the jacketed conductor segment 18 to through-connector 14. As shown at the broken-away section of through-connector 14, another 25 pairs of the 75 conductor pairs received by it from through-connector 12 are electrically terminated in the male terminal members carried by terminal block 28, just as in the case of connector 12. The electrical connection of the terminated conductor pairs in each through-connector to the male terminal members 30 may be performed on a mass production basis such as by using a dip soldering technique. According to this technique, the conductor pairs to be electrically terminated-are bared of their primary insulation and inserted through axial bores in the male terminal members 30. The pins 34 of the terminal members 30 are dipped in a solder bath and the solder rises in the axial bores of the terminal members 30 by virtue of capillary action, Once the solder hardens, a secure electrical as well as mechanical connection is achieved between the individual conductors and their respective male terminal 30. It will be appreciated that electrical connection by this technique cannot be readily made at the site Where the communication cable is to be installed.

Still referring to FIGURES 1 and 2, through-connector 14 after electrically terminating 25 of the 75 pairs received, passes 50 conductor pairs in jacketed cable segment 20 to through-connector 26. This connector electrically terminates 25 pairsand passes the remaining 25 pairs through jacketed cable segment 24 to the terminal connector 22 where they are electrically terminated. Terminal connector 22 is constructed differently from the through-connector 12, 14, and 16 since it is the nal connector of the modular assembly of my invention. This terminal connector however includes a cover -40 constructed of a suitable semi-rigid plastic, a terminalblock 28 mounting a plurality of male terminal members and a guard 32 held together by screws as in the case of the through-connectors. It will be noted that since each of the connectors 12, 14, and 16 and 22 electrically terminate only 25 conductor pairs, the terminal blocks 28 the guards 32 may be identically constructed.

Referring now to FIGURES 3 through 5, the throughconnector cover members 26 each include a top wall 42 and a pair of side walls 44 and 46. The bottom edges of side walls 44 and 46 abut the upper surface of the terminal block 28 when the through-connectors are assembled with screws 36. A collar 48 is integrally formed at one end of the cover member 26 adjacent an entrance opening 50 formed therein. Similarly, a collar 52 is ntegrally formed at the other end of cover member 26 adjacent an exit opening 54. Openings 50 and 54 are joined by a passageway 55 formed by the open interior of the cover member. Opening 50 receives the multiconductor cable 10 or a multiconductor cable segment passed by a preceding through-connector, as the case may be. On the other hand, opening 54 accommodates a multiconductor cable segment running to a succeeding throughconnector or the terminal connector 22, as the case may be.

The collars 48 and 52 are formed each having a pair of ears 56 which initially extend laterally outwardly as best seen in FIGURE 4. After the through-connector receives the cable and/or cable segments, the ears 56 at each end are forced into juxtaposition as seen in phantom in FIGURE 4 causing the collars 48 and 52 to fully embrace the multiconductor cable or cable segments. The collars are slotted, as indicated at 58, to facilitate their manipulation into embracing relation about the cable. Each ear 56 is provided with an aperture 56 for a screw 60 for clamping each collar tightly about the cable or cable segment. Preferably, hole 56 in one of the ears 56 of each collar is threaded to receive the screw 60 thus obviating the necessity for a separate nut.

As seen in FIGURE 3, collar 48 and entrance opening 50 are somewhat larger than collar 52 and exit opening 54 in cover member 26. This is due to the fact that the entrance opening and its adjacent collar accommodate a cable of larger dimensions than does the exit opening and its associated collar. This permits the leading end of the through-connector to be tapered down, thus enhancing the threadability of the modular connector assembly. Since terminal connector 22 has no exit openings, its leading end can be substantially tapered to materially facilitate threading through conduit.

As seen in FIGURE 6, each through-connector as well as the concluding terminal connector 22 of the modular connector assembly receives a separate female connector once the cable is ready for service. In making the electrical connection between each male connector of the assembly and a separate female connector 60 seen in FIGURE 6, the pin guard 32 is removed by unscrewing the screws 36. The female plug receptacle of the connector 60 is then mated with the male terminal members 30 and the connection made secure by screwing the screws 36 into the female connector. Thus the same screws 36 may be used not only to hold the pin guards 32 in place, but also to hold the male and female connectors together during service.

While the present invention contemplates using male electrical connectors in the modular assembly due to the fact that their lateral dimensions are smaller than their female counterparts, it will be appreciated that the teachings of the invention may be applied to a modular assembly employing a series array of female connectors.

The lengths of the jacketed cable segments 18, 20, and 24 are largely a matter of choice depending on the installation. For example, their lengths may be on the order of an inch or two in situations where the connectors are to be installed at only one location. However, the cable segment lengths may also be on the order of several feet or more where it is desired to terminate conrductor pairs at spaced locations in an installation. The

significance of these cable segments lies in the fact that they constitute a fexible connection between connectors thereby permitting the modular assembly to be threaded past bends and curves in conduit.

It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above product without departing from the scope of the invention, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention, which as a matter of language, might be said to fall therebetween.

Having described my invention, what I claim as new Iand desire to secure by Letters Patent is:

1. A modular connector for multiconductor cable comprising, in combination:

(A) a first connector having (l) a first plurality of contact members (a) in number less than total number of conductors in the cable, and

(b) individually electrically connected to the terminal ends of different ones of the conductors,

(2) a through passage accommodating the remaining unconnected conductors of the cable,

(B) a second connector fiexibily joined to said first connector in in-line relation by said remaining conductors which constitute a multiconductor cable segment, said second connector having (1) a second plurality of contact members individually electrically connected to different ones of said remaining conductors of the cable.

2. A modular connector assembly for multiconductor cable of a size capable of being threaded through conduit, said assembly comprising, in combination:

(A) a first connector including (l) a cover having (a) an entrance opening receiving a multiconductor cable,

(b) an exit opening (c) a passageway extending therebetween (2) a terminal block disposed adjacent said passageway (3) a plurality of terminal members embedded in said terminal block, said members (a) extending normal to said passageway in mutually parallel relationship,

(b) the number of said members being less than the total number of conductors of the cable received through said entrance opening, and

(c) individually electrically connected to the terminal ends of different ones of less than all of the conductors of the cable,

(4) the remaining unconnected conductors passing through said exit opennig from said first connector in the form of a jacketed multiconductor cable segment, and

(B) a second connector having (l) a cover including (a) an entrance opening receiving said multiconductor cable segment (2) a terminal block (3) a plurality of terminal members embedded in said block, said members (a) being electrically connected to the terminal ends of conductors of said cable segment.

3. The assembly defined in claim 2 wherein said first and second connector covers further include (l) clamping means disposed adjacent said openings therein for engaging the multiconductor cable and said multiconductor cable segment.

4. The assembly defined in claim 3 wherein said clamping means are integrally formed with said housings.

5. The assembly dened in claim 2 wherein said contact members of said first and second connectors are male contact members.

6. The assembly defined in claim 5 wherein said first and second connectors further include (l) a protective guard having a plurality of holes therein individually receiving said male contact members (a) said guards being releasably attached to said housings.

7. The assembly defined in claim 6 wherein (l) said guards are attached by said screws which also serve upon removal of said guards to secure a complimentary female connector in electrically contacting engagement with the male contact members of sand first and second connectors.

8. The assembly defined in claim 2 wherein there are a plurality of said first connectors all arranged in in-line relationship with said second connector, adjacent ones of said connectors being flexibly joined to one another by jacketed multiconductor cable segments.

9. The assembly defined in claim 8 wherein successive ones of said first connectors are scaled down in size from their predecessors.

10. The assembly defined in claim 4 wherein each said clamping means includes (1) a generally arcuate collar joined to said cover adjacent one of said openings,

(2) a laterally extending ear flexibly joined to each end of said collar (a) said ears adapted to being brought into juxtaposition whereby said collar fully and tightly embraces said cable or cable segment as the case may be, and (3) means holding said ears in juxtaposition.

References Cited UNITED STATES PATENTS 3,167,373 1/1965 Kostich 339-92 X 3,167,375 l/1965 Sarazen 339- X 3,182,280 5/1965 Daut et al. 339-90 X FOREIGN PATENTS 1,423,036 11/1965 France. 50,735 11/1911 Austria.

RICHARD E. MOORE, Primary Examiner U.S. Cl. X.R. 174-72; 339-92, 175 

